Flashlight



Sept- 12, 1967 A. H. MOORE ETAL 3,341,701,

FLASHLIGHT Filed June ll, 1965 3 Sheets-Sheet l` Sept 12, 1967 A, H. MOORE ETAL 3,341,701

FLASHLIGHT Filed June l1, 1965 ."5 Sheets-Sheet 2 r In f Sept 12, 1967 A. H. MOORE ETA; 3,341,701

FLASHLIGHT Filed June ll, 1965 5 Sheets-Sheet. 3

INVENTOR. M 34 @uw HTT R United States Patent O 3,341,701 FLASHLIGHT Arthur H. Moore, Fairfield, and Joseph G. Bacevus, Bridgeport, Conn., assignors to The Bridgeport Metal Goods Manufacturing Company, Bridgeport, Conn., a corporation of Connecticut Filed .lune 11, 1965, Ser. No. 463,262 7 Claims. (Cl. 240-10.65)

ABSTRACT OF THE DISCLOSURE A flashlight having a plastic housing which is longitudinally divided, the two portions being pivoted at one end. A single conductive element mounted in one of the portions serves the plural functions of a battery spring, conductor, switch, and battery retainer.

This invention relates to a flashlight, more particularly, to a flashlight having a housing entirely of plastic construction.

One well known type of prior art flashlight comprises a conductive cylindrical tube open at one end and closed at the other. An electrically conductive spring is mounted in the closed end and a battery of one or more cells is mounted against the spring. The open end is closed by an assembly which includes a lens ring, lens, reflector, lamp holder, and lamp. When this assembly is screwed into position on the flashlight, the terminal of the lamp is forced against the uppermost terminal of the battery, compressing the spring. A switch mounted in the side of the flashlight includes a sliding conductive element for contacting the lamp holder and completing the circuit through the body of the flashlight. Another type of prior art flashlight is similar to the first type described, but mounts the spring on a removable cap for an open end of the tube. Efforts have been made to employ nonconductive housings; however, they usually require a metallic liner to serve as a circuit conducting element.

Prior art flashlights have a number of disadvantages. For example, as will be apparent from the foregoing description, they require a large number of parts and many f these parts must be assembled by riveting, or other expensive techniques. This causes the manufacturing costs to be relatively high and decreases their reliability. Another disadvantage is that, in order to inspect the internal parts for deterioration, it is necessary to remove the cells completely from the flashlight body. Even then, the parts at the closed end of the housing are barely visible. Another disadvantage is that the cylindrical form of flashlight rolls easily'so that it is difficult to cause it to remain stable on a flat surface.

Accordingly, it is a primary object of the present invention to provide an improved flashlight having a housing of all plastic constructiom Other objects are to provide such a flashlight wherein the housing separates longitudinally completely from end to end and the internal parts are carried by one or the other housing parts; wherein a single element serves as battery spring, conductor, switch and friction lock to aid in securely mounting the batteries; wherein all parts are snap-assembled to one another; which requires fewer parts; and which is nonrolling.

3,341,701 Patented Sept. 12, 1967 Hee The manner in which the foregoing objects are achieved will be more apparent from the following description, the appended claims and the figures of the attached drawings, wherein:

FIG. 1 is a plan view of a flashlight constructed in accordance with this invention;

FIG. 2 is a side view of the flashlight illustrating the manner in which the parts of the housing are hinged together; f

FIG. 3 is a bottom view of the flashlight;

FIG. 4 is a front view of the flashlight;

FIG. 5 is a back View of the flashlight;

FIG. 6 is an enlarged detail of the hinge;

FIG. 7 is la vertical longitudinal cross section of the flashlight of the invention;

FIG. 8 is a cross section taken along the line 8 8 of FIG. 7;

FIG. 9 is a cross section taken along the line 9-9 of FIG. 7; Y

FIG. 10 is a cross section taken along the line 10-10 of FIG. 7;

FIG. 11 is a cross section taken along the line 11-11 of FIG. 7;

FIG. 12 is a partial cross section similar to FIG. 7 illustrating the operation of the switch;

FIG. 13 is a partial vertical longitudinal cross section of a modified form of flashlight in accordance with the invention;

FIG. 14 is a front View of the flashlight of FIG. 13, partially broken away to illustrate the hinge construction;

FIG. 15 is a cross section taken substantially along the line 15-15 of FIG. 13;

FIG. 16 is a cross section taken substantially along the line 16-16 of FIG. 13;

FIG. 17 is a front view of the flashlight of FIG. 13 illustrating the manner in which the parts of the housing are assembled; and

FIG. 18 is an enlarged cross sectional detail of the bulb holder portion of the flashlight of FIG. 13.

With particular reference to FIGS. 1-5, there is illustrated a flashlight in accordance with this invention having an elongated, dish shaped base 10 and a somewhat similarly shaped hinged top 12. Base 10 includes a flat bottom surface 14 and right and left angled side walls 16, 18, respectively, terminating in a rim 19. Bottom surface 14 terminates at one end in a hanger 15 defining a hookreceiving opening 17 therein. The bottom surface and side walls include a central ribbed region 20 providing a hand grip. At the front end of the, base, the right and left side walls are joined by a lens ring 22 which is formed with forwardly projecting wings 24 at approximately the midline of the flashlight. Extending outwardly from each of the wings 24 is a molded hinge pin comprising a cylindrical base 26 (FIG. 6) and a horizontally disposed oval head 28.

The top 12 has a configuration roughly similar to the base 10 but reversed. Thus the top includes a flat top surface 30, an angled right side wall 32, and an angled left side wall 34. The side walls terminate in a rim 35. Unlike the base 10, the forward end of top 12 is completely open and fits around lens ring 22. Each of its opposed corners defines an oval hinge opening 36 which is vertically disposed (FIG. 6) when the flashlight is closed. The top and base of the flashlight are assembled by aligning them at 90 and snapping the oval hinge pin heads 28 through the corresponding hinge pin openings 36. The parts may then be rotated relative to each other to the closed position and are thereafter fully hingeable as illustrated in FIG. 2. The base and top are detachably secured together in closed position by latch button 38 (FIGS. 5, 7) on the end of resilient hinge strap 72 that is formed on base and protrudes into latch opening 128 in an outer end wall 126 of top 12 when the flashlight is closed.

The illustrated embodiment of the invention will now be described in detail with particular reference to FIGS. 7-12. The base 10", which is of a suitable plastic material, is formed with a battery chamber having a plurality of transverse battery support ribs 40. The upper edges of the battery support ribs are curved to receive the usual battery of two flashlight dry cells 42 and 44 however, a single elongated dry cell battery could be employed. The rear end of the base is provided with a low shock rib 46 (FIG. 7). A forward barrier wall 48 is provided by the rear surface of a thick shoulder 50 at the forward end of the battery chamber. The spacing between shock rib 46 and barrier 48 is sufficient to receive two dry cells therebetween, as shown in FIG. 7. Extending from the upper surface of shoulder 50 is a pair of vertically projecting lamp supportV cradles 52.

The lens ring 22 has a flat rear surface which is continued by a groove encircling the lower portion of the base to form an annular flange 23 against which is mounted a clear plastic lens 54. At either side of the flange 23 is a thickened wall S6 having a rearwardly directed rib 58, as shown in FIG. 11. Spaced slightly behind the flange 23, at the bottom of the base 10, is a raised shoulder 60 which, in conjunction with the flange 23, defines an arcuate groove. Mounted within this groove and adjacent the lens 54 is the flange 62 of a metallized plastic reflector 64. In the disclosed embodiment, the reflector 64 is noncircular so that the flange 62 exists only at its top and bottom, as seen in FIGS. 11 and 12. The sides of the reflector are retained between the walls 56 and forward of the ribs 58. The lamp-receiving end of the reflector 64 includes a neck 65 having an internal shoulder for receiving the flange 66 of a bayonet type lamp. The lamp includes a cylindrical metallic base 68 which rests on the lamp support cradles 52 and an end terminal 70, which makes contact with the forward terminal of cell 42, as seen in FIGS. 7 and 12.

Intermediate the two ends of base 10, at the sides of the dry cells 42, 44, there are provided opposed pairs of integral molded resilient flaps 74 arranged to retain each of the dry cells in position when the flashlight is opened.

Mounted within top 12 is a resilient metal wire 76 which performs a multiplicity of functions, including those of battery spring, battery retainer, return conductor, and switch. The wire 76 is physically secured within top 12 by a pair of resilient gripping ribs 78 (FIG. 10) which define a pair of opposed grooves into which the wire may be snapped and retained. Proper positioning of the remainder of wire 76 within top 12 is assured by means of a plurality of wire receiving grooves formed within the top 12 by pairs of spaced, inwardly projecting ribs. For example, in the rear end of top 12 there is provided a transverse inner wall 80 having spaced ribs 82 thereon. A pair of spaced ribs 83 are positioned in contact with cell 44 and a pair of ribs 84 are in contact with cell 42. The 4forwardmost end of top 12 includes a pair of spaced guide walls 86, each reinforced by a transverse support wall 88. Guide walls 86 form a guideway 90 therebetween and extend downward far enough to contact the upper side of the lamp base 68 to secure the lamp in position when the flashlight is closed. That end of the wire 76 adjacent the portion which lies between the rib pairs 82 is bent outwardly and upwardly, as shown in FIG. 7, to form a battery spring 92. The central portion of the wire includes adownward offset 94 which bears down against both dry cells when the light is closed and also causes the forward portion of the wire to spring upwardly. This forward portion is bent to include an upwardly extending angular offset 96 which extends through a slot 98 in a switch recess 100 formed in top surface 30. The forwardmost end of wire 76 is bent inward to form a switching contact 102.

A plastic switch button 104 is snap assembled into slot 98 by means of a pair of downwardly extending ribs 106 terminating in outwardly extending shoulders 108. The body of the switch button 104 defines a groove 110 which is triangular in longitudinal cross section, as shown in FIG. 7, to receive the angular offset 96 of the wire 76. The switch button 104 also denes a shallow recess 112, 114 at each end of the groove 110.

Immediately behind the switch recess 100 there are provided a pair of parallel slots 116 extending through the top surface 30. Projecting inwardly from the top surface at the outer edges of the slots` 116 are a pair of spaced lugs 118 terminating in inwardly directed shoulders 120. A permanent magnet is mounted between the lugs 118 with its main body 122 positioned between the lugs 118 and above the shoulders 120-its pole pieces 124 extending through the slots.

The flashlight of this invention can be assembled by merely snapping together its various elements. The manner in which the top 12 is secured to the base 10 has already been described. The switch button 104 is assembled by inserting the lugs 106 into the slot 98 until they spring outward on the inner surface of the flashlight blocking withdrawal of the button by virtue of the shoulders 108.

The magnet is inserted from inside top 12. The pole pieces 124 are forced through the slots 116 until the body of the magnet is secured by the shoulders 120 of lugs 118. The wire 76 is then snapped into position between the ribs 78 and also extends between the various rib pairs 82, 83, and 84 and into guideway 90 between guide walls 86. The angular offset 96 extends into the groove of the switch button 104. The lens 54 and the refiector 64 are then positioned behind the `lens ring 22 and flange 23-the reflector being secured by its lower flange 62 being positioned in the -groove between flange 23 and shoulder 60. The reflector is further secured by the walls 56 and ribs 58. The lamp, having a standard `bayonet socket, is inserted into the small open end of the reflector with its ange 66 positioned in the reflector opening and its base 68 lying in the support cradles 52. The dry cells 42, 44 are then inserted as shown by snapping them between the flaps 74 until they rest upon the battery supports 40.

The flashlight is closed by pivoting top 12 into the closed position. The latch button 38 is forced inward by the bottom edge of the end wall 126 and snaps back into position with latch button 38 in latch opening 128. At the same time, the battery spring 92 is forced into position behind cell 44 exerting forward force through the battery to the reflector. The shock rib 46 maintainsthe dry cell 44 in a position such that its base is spaced from the end ofthe flashlight body. This provides space -for battery spring 92 and prevents excessive shock to, and deformation of, the spring when the flashlight is closed. The downward offset 94 of wire 76 holds the dry cells downward in the flashlight body and springs the forward end of wire 76 upward to seat the angular offset 96 more firmly in the groove 1-10 of switch button 104. To open the flashlight, it is merely necessary to push in on latch button 38, and, simultaneously, raise the back end of top 12.

To operate the light, the switch button 104 is pushed forward by the users thumb and the rear surface of the groove 110 cams the offset 96 and the forward end of wire 76 downward as shown in FIG. 12 until the switching contact 102 touches the lamp base 68. This completes the circuit and causes the lamp to light. By vforcingithe switch button forward a slightly greater distance, the

angular offset 96 will be caused to seat within the recess 112 thus holding the switching contact 102 against the lamp base, even when the switch button is released.

FIGS. 13-18 illustrate a modification of the flashlight of the invention. The basic features of the modified flashlight are similar to the one just described and similar parts are given similar numbers but with a prime attached. However, the construction is simplified by modification of the hinge structure, modification of the battery retaining flaps, and use of a standard bulb holder.

The hinge construction is simplified by omitting the oval-headed hinge pins on the base and substituting cylindrical hinge pins molded on the top. Referring to FIGS. 13 and 14, a base 150 which, in many respects, is Similar to base 10, includes a lens ring 132 at its forward end formed with forwardly projecting wings 134 at approximately the midline of the fiashlight. Each wing defines therein a cylindrical hinge recess 136. The hinged top 138 terminates in a rim 140 and like top 12, is open at its forward end to fit around lens ring 132. Each of its opposed corners has molded thereon an inwardly extending cylindrical hinge pin 142 which is shaped to fit within a corresponding hinge recess 136. The innermost end of each hinge pin is angled to form a camming surface 144. Thus, assembly of top 138 to base 130 is effected by merely sliding the hinge pins 142 downwardly on the lens ring 132, as shown in FIG. 17, until they snap into position in the hinge recesses 136. The natural resilience of the plastic top 138 tends to keep the hinge pins seated in their respective recesses. However, in order to prevent outward springing of rim 140 and consequent disengagement, there is provided a modified support wall 146 having side members extending downwardly adjacent rim 140 at each side of the top, each terminating in a locking lug 148 which engages the inner surface of base 130. Locking lugs 148 thus prevent springing of the top when the top and base are in their closed position.

The modified fiashlight also employs a standard bulb holder. The reflector 150 terminates in a cylindrical neck 152 (FIG. 18) within which is secured a cylindrical metal liner 154 having an inwardly directed annular lip 156 at the end disposed within the reflector portion. The exposed end of liner 154 carries the small diameter end of an outwardly fiaring annular metal cont-act skirt 158 which is positioned to be contacted by the depressed switching contact 102 of wire 76. The plastic cup-shaped bulb holder 160 includes a threaded sleeve 162 which engages an internal thread on liner 154. The base of the bulb holder carries a metal plate 164 secured by a rivet 166. A coil spring 168 is contained within the bulb holder. One end of the spring engages the rivet and metal plate and the other end is positioned within the sleeve 162. A lamp having a cylindrical base 170 and a flange 172 is'positioned within the reflector with the ange bearing against lip 156. The bulb holder 160 is then screwed into position within liner 154. The spring 168 forces the lamp outwardly, causing an electrical connection to be completed between the lamp base 170 and skirt 158 by way of liner 154. At the same time, the spring completes the connection between the lamp end terminal 174 and the rivet 166 which, in turn, is positioned to contact the terminal of dry cell 42. Actuation of switch 104 depresses the switching Contact 102 as previously described but the electrical circuit is completed at skirt 158.

Another distinction between the modified flashlight and that previously illustrated is that a single elongated molded resilient b-attery retaining fiap 176 is provided on each side of the base 130. In the previously described embodiment, a pair of fiaps was provided for each dry cell.

It will now be seen that all the objects set forth above have been achieved by the flashlight of this invention. Furthermore, it will be apparent to those skilled in the art that a number of variations and modifications may be made in the invention without departing from its spirit and scope. Accordingly, the foregoing description is to be construed as illustrative only, rather than limiting. This invention is limited only by the scope of the following claims.

What we claim as new and desire to secure by Letters Patent of the United States is:

1. A flashlight which comprises: an elongated, dish shaped, nonconductive base member having a first and a second end, said first end being substantially open; an elongated, dish shaped, nonconductive top member having an open first end and a second end, and defining a longitudinal slot; hinge means interconnecting the first ends of said base and top members; latch means positioned to selectively interlock the second ends of said base and top members to form a substantially hollow housing; reflector means mounted in the first end of said base member, said reflector means defining a lamp-receiving opening; a lamp supporting cradle in said base member adjacent said lamp-receiving opening to support the base of a lamp extending through said lamp-receiving opening; lamp base gripping means in said top member positioned to bear against said lamp base to seat it securely in said cradle when said top and base members are closed; a switch button slidably mounted in said longitudinal slot and defining a recess therein bounded by a camming surface; elongated wire means carried by said top member having a resilient first end normally spaced from said lamp base, an angular offset portion adjacent its first end disposed within the switch button recess to be carnrned inwardly by said camming surface upon sliding of the switch button in said slot, and a resilient second end -arranged to bear against the base of a battery contained within said base member and in electrical contact with said lamp when said top and base members are closed.

2. The flashlight of claim 1 wherein said hinge means comprises: first and second cylindrical hinge pins on said base member, each terminating in a noncircular head; and first and second openings on said top member disposed Iabout said hinge pins.

3. The fiashlight of claim 1 wherein the second end of said top member defines a latching opening and said latch means comprises: a resilient strap having a first end integral with said base member and a second end terminating in a latch button engageable in said latching opening.

4. The iiashlight of claim 1 wherein said top member includes a pair of resilient opposed ribs in gripping engagement with said wire means.

5. The flashlight of claim 1 wherein said lamp base gripping means comprises a pair of longitudinally extending wall portions defining a guideway therebetween enclosing the first end of said wire means therebetween.

6. The fiashlight of claim 1 wherein said top member defines a pair of spaced parallel slots therethrough and includes a magnet having its poles extending outwardly through said slots and a pair of resilient shouldered lugs retaining said magnet thereon.

7. A ashlight which comprises: an elongated nonconductive housing base member; an elongated nonconductive housing top member; hinge means pivotally interconnecting said top and base members in detachably secured relationship to form a longitudinally separated housing; an opening in one of said members at one end; a reflector adjacent said opening defining a lamp-receiving aperture; cradle means in said base member for supporting one side of'a lamp base; clamping means in said top member arranged to bear against the other isde of said lamp base when said base and top members are closed; elongated conductive wire means carried by one of said members having a resilient first end normally out of contact with, but arranged torbe selectively depressed to make electrical contact with, a first terminal of a lamp positioned by said cradle means and the clamping means and a resilient second end disposed to bear against the base of a battery contained within said housing and in contact 7 with a second terminal of said lamptand manually operable switch means for selectively depressing the first end of said wire means to complete a circuit through said lamp, battery, and conductive wire means.

References Cited UNITED STATES PATENTS 8 3,017,502 1/1962 Dent 24U- 10.68 3,105,233 9/1963 DAmoreet al. 24U-10.66 XR 3,256,428 6/ 1966 Schwartz Z140-10.65

FOREIGN PATENTS 344,513 11/1921 Germany. 374,306 4/ 1923 Germany.

ld :3:33:33: 8113222 NORTON ANSHERPf-fmafy 2,886,664 5/1959 Graubner 24o-52.5 XR 10 D. L. JACOBSON, Examiner. 

1. A FLASHLIGHT WHICH COMPRISES: AN ELONGATED DISH SHAPED, NONCONDUCTIVE BASE MEMBER HAVING A FIRST AND A SECOND END, SAID FIRST END BEING SUBSTNATIALLY OPEN; AN ELONGATED, DISH SHAPED, NONCONDUCTIVE TOP MEMBER HAVING AN OPEN FIRST END AND A SECOND END, AND DEFINING A LONGITUDINAL SLOT; HINGE MEANS INTERCONNECTING THE FIRST ENDS OF SAID BASE AND TOP MEMBERS; LATCH MEANS POSITIONED TO SELECTIVELY INTERLOCK THE SECOND ENDS OF SAID BASE AND TOP MEMBERS TO FORM A SUBSTANTIALLY HOLLOW HOUSING; REFLECTOR MEANS MOUNTED IN THE FIRST END OF SAID BASE MEMBER, SAID REFLECTOR MEANS DEFINING A LAMP-RECEIVING OPENING; A LAMP SUPPORTING CRADLE IN SAID BASE MEMBER ADJACENT SAID LAMP-RECEIVING OPENING TO SUPPORT THE BASE OF A LAMP EXTENDING THROUGH SAID LAMP-RECEIVING OPENING; LAMP BASE GRIPPING MEANS IN SAID TOP MEMBER POSITIONED TO BEAR AGAINST SAID LAMMP BASE TO SEAT IT SECURELY IN SAID CRADLE WHEN SAID TOP AND BASE MEMBERS ARE CLOSED; A SWITCH BUTTON SLIDABLY MOUNTED IN SAID LONGITUDINAL SLOT AND DEFINING A RECESS THEREIN BOUNDED BY A CAMMING SURFACE; ELONGATED WIRE MEANS CARRIED BY SAID TOP MEMBER HAVING A RESILIENT FIRST END NORMALLY SPACED FROM SAID LAMP BASE, AND ANGULAR OFFSET PORTION ADJACENT ITS FIRST END DISPOSED WITHIN THE SWITCH BUTTON RECESS TO BE CAMMED INWARDLY BY SAID CAMMING SURFACE UPON SLIDING OF THE SWITCH BUTTON IN SAID SLOT, AND A RESILIENT SECOND END ARRANGED TO BEAR AGAINST THE BASE OF A BATTERY CONTAINED WITHIN SAID BASE MEMBER AND IN ELECTRICAL CONTACT WITH SAID LAMP WHEN SID TOP AND BASE MEMBERS ARE CLOSED. 